Additive manufacture of casing liner in a wellbore

ABSTRACT

Provided are systems and methods for forming a casing liner in a wellbore of a hydrocarbon well. The forming including disposing a casing liner print head in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore, and conducting a downhole lining operation including operating the casing liner print head to eject casing liner material into the annular region to form, in the annular region, a casing liner including elongated voids formed in the casing liner material.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/594,676 filed on Dec. 5, 2017 and titled “ADDITIVEMANUFACTURE OF CEMENTITIOUS MATERIALS IN A WELLBORE” which is herebyincorporated by reference in its entirety.

FIELD

Embodiments relate generally to developing wells, and more particularlyto additive manufacture of cementitious materials in a wellbore of awell.

BACKGROUND

A well includes a wellbore (or “borehole”) that is drilled into theearth to provide access to a subsurface formation (a geographicformation below the earth's surface) to facilitate the extraction ofnatural resources, such as hydrocarbons and water from the subsurfaceformation, to facilitate the injection of fluids into the subsurfaceformation, or to facilitate the evaluation and monitoring of thesubsurface formation. In the petroleum industry, wells are often drilledto extract (or “produce”) hydrocarbons, such as oil and gas, fromsubsurface formations. The term “oil well” is used to refer to a welldesigned to produce oil. In the case of an oil well, some natural gas istypically produced along with oil. A well producing both oil and naturalgas is sometimes referred to as an “oil and gas well” or “oil well.”

Creating an oil well typically involves several stages, including adrilling stage, a completion stage and a production stage. The drillingstage normally involves drilling a wellbore into a subsurface formationthat is expected to contain a concentration of hydrocarbons that can beproduced. The portion of the subsurface formation expected to containhydrocarbons is often referred to as a “hydrocarbon reservoir” or“reservoir.” The drilling process is usually facilitated by a drillingrig that sits at the earth's surface. The drilling rig provides foroperating a drill bit to cut the wellbore, hoisting, lowering andturning drill pipe and tools, circulating drilling fluids in thewellbore, and generally controlling various operations in the wellbore(or “down-hole” operations). The completion stage involves making thewell ready to produce hydrocarbons. In some instances, the completionstage includes installing casing pipe into the wellbore, cementing thecasing in place, perforating the casing pipe and cement, installingproduction tubing, and pumping fluids into the well to fracture, cleanor otherwise prepare the reservoir and well to produce hydrocarbons. Theproduction stage involves producing hydrocarbons from the reservoir byway of the well. During the production stage, the drilling rig isnormally removed and replaced with a collection of valves, oftenreferred to as a “production tree”, that regulates pressure in thewellbore, controls production flow from the wellbore and provides accessto the wellbore in the event further completion work is needed. A pumpjack or other mechanism is sometimes used to provide lift that assistsin extracting hydrocarbons from the reservoir, especially in instanceswhere the pressure in the well is so low that the hydrocarbons do notflow freely to the surface. Flow from an outlet valve of the productiontree is normally connected to a distribution network of midstreamfacilities, such as tanks, pipelines and transport vehicles thattransport the production to downstream facilities, such as refineriesand export terminals.

A casing operation of a well completion can be particularly importantfor establishing the integrity of the well. The casing assembly usuallyincludes a large diameter rigid casing pipe (for example,hollow-cylindrical steel pipe) that is inserted into the wellbore and isheld in place by a hardened material, such as cement, disposed in anannular region formed between an exterior of the casing pipe and thewall of the wellbore. A casing operation typically includes lowering thecasing pipe into the wellbore and pumping cement into the annular regionto secure the casing pipe in place and effectively seal the annularregion to prevent fluids and gasses from moving through the annularregion. During completion operations the casing pipe and cement areoften perforated to provide fluid communication with the surroundingportion of the reservoir. For example, in the case of a production oilwell in which a given depth interval of the reservoir is expected tocontain oil and gas, perforations can be made in the casing pipe andcement across the depth interval to facilitate the flow of oil and gasfrom the reservoir, into the interior of the casing pipe. During theproduction stage, the interior of casing pipe, or production tubinglocated inside the casing, can serve as a conduit to direct the oil andgas to the surface.

In a traditional well the casing system often contains multipleintervals of casing successively placed within previous casing runs thatextend deep into the wellbore. These can include, for example, aconductor pipe extending from the earth's surface into a first depthinterval, surface casing extending from the conductor pipe into a seconddepth interval, intermediate casing extending from the surface casinginto a third depth interval, and production casing extending from theintermediate casing into a fourth depth interval. The production casingmay, for example, include perforations that provide fluid communicationwith a production zone of the surrounding reservoir within the fourthdepth interval. The casing typically serves multiple functions that arecritical to operating and maintaining integrity of the well. The casingcan prevent the formation from caving into the wellbore (for example, byproviding a rigid structure lining the wellbore), can provide forcontrol of downhole pressure (for example, by sealing the annular regionto direct pressurized formation fluids into the interior of the casingwhere it can be controlled by valves coupled to the casing), and canprovide for selective isolation of different portions of the formation(for example, by sealing-off a first depth interval of the wellbore toinhibit water production across the first depth interval and providing aconduit for oil production from a second depth interval whereperforations are present).

SUMMARY

Applicant has recognized that existing techniques for casings wells haveshortcomings. For example, traditional casing operations may not providea suitable level of structural integrity. In many instances, a casingoperation involves installing a casing pipe into a wellbore and acementing operation to secure the casing pipe in the wellbore. Thecementing operation normally involves determining a volume of an annularregion formed between an exterior of the casing pipe and the wall of thewellbore to be filled with cement, pumping the determined volume ofcement into the annular region, and allowing the cement to harden to fixthe casing pipe in place. This can include, for example, pumping avolume of cement slurry down through an interior of the casing pipe,where it is expelled from a down-hole end of the casing and movesup-hole into the annular region, to fill the annular region.Unfortunately, the movement and placement of the cement can be difficultto predict and track, and is prone to forming inconsistencies that cancompromise the integrity of the cement. For example, imprecise placementof the cement may create undesirable voids in the cement that can leadto unexpected fractures, and even catastrophic ruptures when the cementis exposed to high pressure fluids in the wellbore. Given the importanceof cement integrity, well operators dedicate a significant amount oftime and money to inspect and monitor the cement, both at the time ofinstallation and over the life of the well. For example, a well operatormay regularly conduct logging operations to assess the condition of thecement over the life of a well. Thus, traditional casing operations mayintroduce inconsistencies that have to be identified and monitored,thereby adding to the complexity, risks and costs of developing andoperating a well.

As a further example of a shortcoming, traditional casing operations canbe time consuming and costly. In many instances, a casing operationrequires a significant amount of time to place the casing pipe andcement the casing pipe in place, and requires other operations to besuspended while the casing operation is completed. For example, after afirst depth interval of a well is drilled, a drilling string (forexample, including drill pipe and a drill bit) may be removed, a firstinterval of casing pipe may be positioned in the first depth interval ofthe wellbore, cement slurry may be pumped into the annular region,additional time may be taken to allow the cement to harden, and, oncethe cement has hardened, the drilling of the next depth interval mayproceed. This can include, for example, drilling out the hardened cementat the bottom of the casing and proceeding to drill deeper into theformation. Thus, traditional casing operations can require a stop-startapproach that requires additional runs and operations (for example,pulling a drill string, running the casing pipe, cementing the casingpipe in place, and re-running the drill string) that increase the timeand costs for drilling and completing a well.

Recognizing these and other shortcomings of existing well casingoperations, Applicant has developed novel systems and methods for casingwells. In some embodiments, a casing operation for a wellbore employs anadditive manufacturing (AM) technique, such as three-dimensional (3D)printing, to deposit a wellbore lining material, such as cement, in thewellbore. For example, an additive printing device, such as a 3D cementprinting head, may be positioned in an annular region of the wellbore,located between an exterior of casing pipe positioned in the wellboreand the wall of the wellbore. The additive printing device may beoperated to precisely deposit layers of cement in the annular region asit is advanced along a length of the annular region of the wellbore tocreate printed layers of a casing liner that, in combination, form avolume of a printed casing liner that fills a depth interval of theannular region. Advantageously, the precise incremental placement of thecasing liner material can help to ensure that the casing liner materialis deposited in specific locations and does not include inconsistencies,such as unwanted voids, that can negatively impact the mechanicalproperties of the casing liner and compromise the integrity of thecasing. For example, the additive manufacture of the cement can enablethe precise control and monitoring of the amount of cement deposited ineach location within the annular region to form a printed cement casingliner.

In some embodiments, the additive printing device includes a printinghead having one or more nozzles that deliver the wellbore liningmaterial to particular locations within the wellbore. For example, theadditive printing device may include a 3D cement printing head havingone or more nozzles that eject the casing liner material, such ascement, to particular locations within the annular region. In someembodiments, the one or more nozzles include nozzles for depositingdifferent materials that form the printed casing liner. For example, theone or more nozzles may include a set of cement nozzles for depositingcement, and a set of additive nozzles for depositing additives, such aspolymers, that can be deposited with the cement to form the printedcement casing. Such an arrangement may enable multiple materials to bedeposited simultaneous during a cementing operation to form a printedcasing liner that includes a cementitious matrix of cement and othermaterials.

In some embodiments, the printed casing liner is formed to includeintegrated structures that modify mechanical properties of the casingliner. In some embodiments, the integrated structures include volumeswithin the printed casing liner that are void of the casing linermaterial. For example an integrated structure may include a void in theprinted casing cement liner that includes a volume of a gas, liquid orsolid (other than cement material) that is encapsulated in the cementmaterial. In some embodiments, the integrated structures arestrategically positioned and shaped to effect particular modificationsto the mechanical properties of the casing liner, such as ductility orimpact resistance. For example, the printed cement casing liner may beprinted to include a pattern of integrated structures extending in aradial or longitudinal direction of the wellbore. Such integratedstructures may reduce the Young's Modulus of the printed casing cement(relative to that of a solid cement structure) in the radial orlongitudinal direction, thereby enabling the cement to deform radiallyor longitudinally to absorb variations in radial or longitudinalstresses acting on the printed cement casing liner, without cracking orotherwise failing.

In some embodiments, an integrated structure is formed in the wellboreindependent of the depositing of the casing liner material. For example,an integrated structure, such as a honeycomb shaped polymer material,may be printed in the annular region of the wellbore to from anintegrated structure having contiguous voids formed in the structure.Then, cement material may be injected into the contiguous voids of theintegrated structure to form a printed casing liner formed of acementitious matrix of the cement material and integrated structurematerial. In some embodiments, the casing liner material is formed inthe wellbore independent of the integrated structures. For example, thecement material may be printed in the annular region of the wellborewith one or more contiguous integrated void structures formed in thecement material, such as a contiguous honeycomb shaped void structure.Then, an integrated structure material, such as a polymer, may beinjected into the one or more contiguous integrated void structures ofthe printed cement material to form a printed casing liner formed of acementitious matrix of the cement material and the additive materialstructure.

Provided in some embodiments is a method that includes drilling awellbore into a subsurface formation, positioning casing pipe in thewellbore, and conducting a cementing operation including additivemanufacture of a casing liner in an annular region between an exteriorof the casing pipe and a wall of the wellbore.

In some embodiments, the casing liner includes a cementitious materialand the cementing operation includes a print head depositing thecementitious material into position to form the casing liner as theprint head is advanced within the annular region. In certainembodiments, the casing liner includes a casing liner material and oneor more integrated structures formed in the casing liner material. Insome embodiments, the casing liner material includes cement. In certainembodiments, at least one of the one or more integrated structuresincludes a void in the casing liner material containing a substanceother than the cement. In some embodiments, the substance includes agas, a fluid or a solid other than the cement. In some embodiments, theone or more integrated structures include elongated voids in the casingliner material extending in a radial direction in the annular region andcontaining a substance having a Young's Modulus that is less than aYoung's Modulus of the casing liner material such that the casing linerhas a Young's Modulus in the radial direction that is less than theYoung's Modulus of the casing liner material. In certain embodiments,the integrated structures include elongated voids in the casing linermaterial extending in a longitudinal direction in the annular region andcontaining a substance having a Young's Modulus that is less than aYoung's Modulus of the casing liner material such that the casing linerhas a Young's Modulus in the longitudinal direction that is less thanthe Young's Modulus of the casing liner material. In some embodiments,the additive manufacture of the casing liner includes additivemanufacture of an integrated structure in the annular region (theintegrated structure having one or more voids formed therein) and thecementing operation further includes injecting a cementitious materialinto the one or more voids of the integrated structure.

In certain embodiments, the additive manufacture of the casing linerincludes additive manufacture of a cement structure in the annularregion (the cement structure having one or more voids formed therein)and the cementing operation further includes injecting a substance intothe one or more voids of the cement structure. In some embodiments,positioning the casing pipe in the wellbore includes conducting additivemanufacture of the casing pipe in the wellbore. In some embodiments, theadditive manufacture of a casing liner in the annular region and theadditive manufacturing of the casing pipe in the wellbore includeforming one or more perforations in the casing liner and the casing pipeto facilitate flow of substances between the formation and a centralpassage of the casing pipe.

Provided in some embodiments is a well system that includes an additivemanufacture device including a print head including one or more nozzlesadapted to deposit casing liner material in a wellbore of a well, and awell control system adapted to perform a cementing operation includingcontrolling the additive manufacture device to perform an additivemanufacture of a casing liner in the wellbore including depositing thecasing liner material in an annular region of the wellbore locatedbetween an exterior of a casing pipe positioned in the wellbore and awall of the wellbore to form a casing liner in the wellbore.

In some embodiments, the casing liner material includes a cementitiousmaterial and the cementing operation includes controlling the print headto advance within the annular region and deposit the cementitiousmaterial into position to form the casing liner as the print head isadvanced within the annular region. In certain embodiments, the casingliner includes a casing liner material and one or more integratedstructures formed in the casing liner material. In some embodiments, thecasing liner material includes cement. In certain embodiments, at leastone of the one or more integrated structures includes a void in thecasing liner material containing a substance other than the cement. Insome embodiments, the substance includes a gas, a fluid or a solid otherthan the cement. In certain embodiments, the one or more integratedstructures include elongated voids in the casing liner materialextending in a radial direction in the annular region and containing asubstance having a Young's Modulus that is less than a Young's Modulusof the casing liner material such that the casing liner has a Young'sModulus in the radial direction that is less than the Young's Modulus ofthe casing liner material. In some embodiments, the integratedstructures include elongated voids in the casing liner materialextending in a longitudinal direction in the annular region andcontaining a substance having a Young's Modulus that is less than aYoung's Modulus of the casing liner material such that the casing linerhas a Young's Modulus in the longitudinal direction that is less thanthe Young's Modulus of the casing liner material.

In certain embodiments, the additive manufacture of the casing linerincludes additive manufacture of an integrated structure in the annularregion (the integrated structure having one or more voids formedtherein) and the cementing operation further includes controllinginjection of a cementitious material into the one or more voids of theintegrated structure. In some embodiments, the additive manufacture ofthe casing liner includes additive manufacture of a cement structure inthe annular region (the cement structure having one or more voids formedtherein) and the cementing operation further includes controllinginjection of a substance into the one or more voids of the cementstructure. In some embodiments, the well control system is furtheradapted to perform a casing pipe operation including controlling theadditive manufacture device to perform an additive manufacture of thecasing pipe in the wellbore. In some embodiments, the additivemanufacture of a casing liner in the annular region and the additivemanufacturing of the casing pipe in the wellbore include forming one ormore perforations in the casing liner and the casing pipe to facilitateflow of substances between the formation and a central passage of thecasing pipe.

Provided in some embodiments, is a non-transitory computer readablemedium including program instructions stored thereon that are executableby a processor to cause the operations of drilling a wellbore into asubsurface formation, positioning casing pipe in the wellbore, andconducting a cementing operation including additive manufacture of acasing liner in an annular region between an exterior of the casing pipeand a wall of the wellbore.

In some embodiments, the casing liner includes a cementitious materialand the cementing operation includes a print head depositing thecementitious material into position to form the casing liner as theprint head is advanced within the annular region. In certainembodiments, the casing liner includes a casing liner material and oneor more integrated structures formed in the casing liner material. Insome embodiments, the casing liner material includes cement. In certainembodiments, at least one of the one or more integrated structuresincludes a void in the casing liner material containing a substanceother than the cement. In some embodiments, the substance includes agas, a fluid or a solid other than the cement. In certain embodiments,the one or more integrated structures include elongated voids in thecasing liner material extending in a radial direction in the annularregion and containing a substance having a Young's Modulus that is lessthan a Young's Modulus of the casing liner material such that the casingliner has a Young's Modulus in the radial direction that is less thanthe Young's Modulus of the casing liner material. In some embodiments,the integrated structures include elongated voids in the casing linermaterial extending in a longitudinal direction in the annular region andcontaining a substance having a Young's Modulus that is less than aYoung's Modulus of the casing liner material such that the casing linerhas a Young's Modulus in the longitudinal direction that is less thanthe Young's Modulus of the casing liner material.

In certain embodiments, the additive manufacture of the casing linerincludes additive manufacture of an integrated structure in the annularregion (the integrated structure having one or more voids formedtherein) and the cementing operation further includes injecting acementitious material into the one or more voids of the integratedstructure. In some embodiments, the additive manufacture of the casingliner includes additive manufacture of a cement structure in the annularregion (the cement structure having one or more voids formed therein)and the cementing operation further includes injecting a substance intothe one or more voids of the cement structure. In certain embodiments,positioning the casing pipe in the wellbore includes conducting additivemanufacture of the casing pipe in the wellbore. In some embodiments, theadditive manufacture of a casing liner in the annular region and theadditive manufacturing of the casing pipe in the wellbore includeforming one or more perforations in the casing liner and the casing pipeto facilitate flow of substances between the formation and a centralpassage of the casing pipe.

Provided in some embodiments is a method of forming a casing liner in awellbore of a hydrocarbon well. The method including disposing a casingliner print head in an annular region located between a casing pipedisposed in a wellbore of a hydrocarbon well and a wall of the wellbore,and conducting a downhole lining operation including operating thecasing liner print head to eject casing liner material into the annularregion to form, in the annular region, a casing liner includingelongated voids formed in the casing liner material.

In some embodiments, the downhole lining operation includes advancingthe casing liner print head along a length of the wellbore and ejectingthe casing liner material along a length of the annular region to formthe casing liner along the length of the annular region. In certainembodiments, the elongated voids include elongated voids extending in aradial direction in the annular region. In some embodiments, theelongated voids include elongated voids extending in a longitudinaldirection in the annular region. In certain embodiments, the elongatedvoids are encapsulated within the casing liner material. In someembodiments, the elongated voids include elliptical shaped voids. Incertain embodiments, the lining operation includes ejecting anintegrated structure material to form the elongated voids in the casingliner material. In some embodiments, the integrated structure materialincludes a gas, liquid or solid. In certain embodiments, the integratedstructure material includes a polymer. In some embodiments, theintegrated structure material has a Young's Modulus that is less than aYoung's Modulus of the casing liner material. In some embodiments, thecasing liner material includes a cementitious material. In someembodiments, the casing liner material includes casing cement.

Provided in some embodiments is a wellbore casing liner printing systemthat includes a casing liner print head adapted to be disposed in anannular region located between a casing pipe disposed in a wellbore of ahydrocarbon well and a wall of the wellbore. The casing liner print headadapted to eject casing liner material into the annular region to form,in the annular region, a casing liner including elongated voids formedin the casing liner material.

In some embodiments, the casing liner print head is adapted to beadvanced along a length of the wellbore and to eject the casing linermaterial along a length of the annular region to form the casing lineralong the length of the annular region. In certain embodiments, theelongated voids include elongated voids extending in a radial directionin the annular region. In some embodiments, the elongated voids includeelongated voids extending in a longitudinal direction in the annularregion. In certain embodiments, the elongated voids are encapsulatedwithin the casing liner material. In some embodiments, the elongatedvoids include elliptical shaped voids. In certain embodiments, thecasing liner print head is adapted to eject an integrated structurematerial to form the elongated voids in the casing liner material. Insome embodiments, the integrated structure material includes a gas,liquid or solid. In certain embodiments, the integrated structurematerial includes a polymer. In some embodiments, the integratedstructure material has a Young's Modulus that is less than a Young'sModulus of the casing liner material. In certain embodiments, the casingliner material includes a cementitious material. In some embodiments,the casing liner material includes casing cement.

Provided in some embodiments is a method of forming a casing liner in awellbore of a hydrocarbon well. The method including disposing a casingliner print head in an annular region located between a casing pipedisposed in a wellbore of a hydrocarbon well and a wall of the wellbore,and conducting a downhole cementing operation including operating thecasing liner print head to eject casing cement into the annular regionto form, in the annular region, a casing liner including elongated voidsformed in the cementitious material. In some embodiments, the downholecementing operation includes advancing the casing liner print head alonga length of the wellbore and ejecting the casing liner material along alength of the annular region to form the casing liner along the lengthof the annular region.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is diagram that illustrates a well environment in accordance withone or more embodiments.

FIGS. 2A and 2B are diagrams that illustrate an example casing linerformed by way of an additive manufacturing process in accordance withone or more embodiments.

FIG. 3 is a diagram that illustrates an example of casing linerincluding integrated structures in accordance with one or moreembodiments.

FIGS. 4A and 4B are diagrams that illustrate an example casing linerincluding integrated structures formed by way of an additivemanufacturing process in accordance with one or more embodiments.

FIGS. 5A and 5B are diagrams that illustrate an example casing linercontaining radially oriented integrated structures in accordance withone or more embodiments.

FIGS. 6A and 6B are diagrams that illustrate an example casing linercontaining longitudinally oriented integrated structures in accordancewith one or more embodiments.

FIGS. 7A-7N are diagrams that illustrate an example structures inaccordance with one or more embodiments.

FIG. 8 is a flowchart that illustrates a method of printing a casingliner in accordance with one or more embodiments.

FIGS. 9A and 9B are diagrams that illustrate an example casing formed byway of an additive manufacturing process in accordance with one or moreembodiments.

FIG. 10 is a diagram that illustrates printing casing having integratedstructures, including perforations in accordance with one or moreembodiments.

FIG. 11 is a flowchart that illustrates a method of printing a casing inaccordance with one or more embodiments.

FIG. 12 is a diagram that illustrates an example computer system inaccordance with one or more embodiments.

While this disclosure is susceptible to various modifications andalternative forms, specific embodiments are shown by way of example inthe drawings and will be described in detail. The drawings may not be toscale. It should be understood that the drawings and the detaileddescriptions are not intended to limit the disclosure to the particularform disclosed, but are intended to disclose modifications, equivalents,and alternatives falling within the spirit and scope of the presentdisclosure as defined by the claims.

DETAILED DESCRIPTION

Described are embodiments of systems and methods for casing wells. Insome embodiments, a casing operation for a wellbore employs an additivemanufacturing (AM) technique, such as three-dimensional (3D) printing,to deposit a wellbore lining material, such as cement, in the wellbore.For example, an additive printing device, such as a 3D cement printinghead, may be positioned in an annular region of the wellbore, locatedbetween an exterior of casing pipe positioned in the wellbore and thewall of the wellbore. The additive printing device may be operated toprecisely deposit layers of cement in the annular region as it isadvanced along a length of the annular region of the wellbore to createprinted layers of a casing liner that, in combination, form a volume ofa printed casing liner that fills a depth interval of the annularregion. Advantageously, the precise incremental placement of the casingliner material can help to ensure that the casing liner material isdeposited in specific locations and does not include inconsistencies,such as unwanted voids, that can negatively impact the mechanicalproperties of the casing liner and compromise the integrity of thecasing. For example, the additive manufacture of the cement can enablethe precise control and monitoring of the amount of cement deposited ineach location within the annular region to form a printed cement casingliner.

In some embodiments, the additive printing device includes a printinghead having one or more nozzles that deliver the wellbore liningmaterial to particular locations within the wellbore. For example, theadditive printing device may include a 3D cement printing head havingone or more nozzles that eject the casing liner material, such ascement, to particular locations within the annular region. In someembodiments, the one or more nozzles include nozzles for depositingdifferent materials that form the printed casing liner. For example, theone or more nozzles may include a set of cement nozzles for depositingcement, and a set of additive nozzles for depositing additives, such aspolymers, that can be deposited with the cement to form the printedcement casing. Such an arrangement may enable multiple materials to bedeposited simultaneous during a cementing operation to form a printedcasing liner that includes a cementitious matrix of cement and othermaterials.

In some embodiments, the printed casing liner is formed to includeintegrated structures that modify mechanical properties of the casingliner. In some embodiments, the integrated structures include volumeswithin the printed casing liner that are void of the casing linermaterial. For example an integrated structure may include a void in theprinted casing cement liner that includes a volume of a gas, liquid orsolid (other than cement material) that is encapsulated in the cementmaterial. In some embodiments, the integrated structures arestrategically positioned and shaped to effect particular modificationsto the mechanical properties of the casing liner, such as ductility orimpact resistance. For example, the printed cement casing liner may beprinted to include a pattern of integrated structures extending in aradial or longitudinal direction of the wellbore. Such integratedstructures may reduce the Young's Modulus of the printed casing cement(relative to that of a solid cement structure) in the radial orlongitudinal direction, thereby enabling the cement to deform radiallyor longitudinally to absorb variations in radial or longitudinalstresses acting on the printed cement casing liner, without cracking orotherwise failing.

In some embodiments, an integrated structure is formed in the wellboreindependent of the depositing of the casing liner material. For example,an integrated structure, such as a honeycomb shaped polymer material,may be printed in the annular region of the wellbore to from anintegrated structure having contiguous voids formed in the structure.Then, cement material may be injected into the contiguous voids of theintegrated structure to form a printed casing liner formed of acementitious matrix of the cement material and integrated structurematerial. In some embodiments, the casing liner material is formed inthe wellbore independent of the integrated structures. For example, thecement material may be printed in the annular region of the wellborewith one or more contiguous integrated void structures formed in thecement material, such as a contiguous honeycomb shaped void structure.Then, an integrated structure material, such as a polymer, may beinjected into the one or more contiguous integrated void structures ofthe printed cement material to form a printed casing liner formed of acementitious matrix of the cement material and the additive materialstructure.

FIG. 1 is diagram that illustrates a well environment 100 in accordancewith one or more embodiments. In the illustrated embodiment, the wellenvironment 100 includes a hydrocarbon reservoir (“reservoir”) 102located in a subsurface formation (“formation”) 104 and a well system(“well”) 106.

The formation 104 may include a porous or fractured rock formation thatresides underground, beneath the earth's surface (“surface”) 108. In thecase of the well 106 being a hydrocarbon well, the reservoir 102 mayinclude a portion of the formation 104 that contains (or is at leastdetermined to or expected to contain) a subsurface pool of hydrocarbons,such as oil and gas. The formation 104 and the reservoir 102 may eachinclude different layers of rock having varying characteristics, such asvarying degrees of permeability, porosity, and resistivity. In the caseof the well 106 being operated as a production well, the well 106 mayfacilitate the extraction (or “production”) of hydrocarbons from thereservoir 102. In the case of the well 106 being operated as aninjection well, the well 106 may facilitate the injection of fluids,such as water, into the reservoir 102. In the case of the well 106 beingoperated as a monitoring well, the well 106 may facilitate themonitoring of characteristics of the reservoir 102, such reservoirpressure or water encroachment.

The well 106 may include a wellbore 120, a well control system (“controlsystem”) 122 and a well casing system 124. The well control system 122may control various operations of the well 106, such as well drillingoperations, well completion operations, well injection operations, andwell and formation monitoring operations. In some embodiments, the wellcontrol system 122 includes a computer system that is the same as orsimilar to that of computer system 2000 described with regard to atleast FIG. 12.

The wellbore 120 may include a bored hole that extends from the surface108 into a target zone of the formation 104, such as the reservoir 102.An upper end of the wellbore 120 at or near the surface 108 may bereferred to as the “up-hole” end of the wellbore 120, and a lower end ofthe wellbore 120 terminating in the formation 104 may be referred to asthe “down-hole” end of the wellbore 120. The wellbore 120 may becreated, for example, by a drill bit boring through the formation 104and the reservoir 102. The wellbore 120 can provide for the circulationof drilling fluids during drilling operations, the flow of hydrocarbons(for example, oil and gas) from the reservoir 102 to the surface 108during production operations, the injection of substances (for example,water) into one or both of the formation 104 and the reservoir 102during injection operations, or the communication of monitoring devices(for example, logging tools) into one or both of the formation 104 andthe reservoir 102 during monitoring operations (for example, during insitu logging operations).

In some embodiments, the wellbore 120 includes cased or uncasedportions. For example the wellbore 120 may have a cased portion 132 andan uncased (or “open-hole”) portion 134. The cased portion 132 mayinclude a portion of the wellbore 120 having casing 140 of the wellcasing system 124 disposed in that portion. The uncased portion 134 mayinclude a portion of the wellbore 120 not having casing 140 disposed inthat portion.

In some embodiments, the casing 140 includes an annular casing thatlines the wall of the wellbore 120 to define a central passage 142 thatprovides a conduit for the transport of tools and substances through thewellbore 120. For example, the central passage 142 may provide a conduitfor lowering logging tools into the wellbore 120, a conduit for the flowof production substances, such as oil and gas, from the reservoir 102 tothe surface 108, or a conduit for the flow of injection substances, suchas water, from the surface 108 into the formation 104. In someembodiments, the casing 140 includes perforations 144. The perforations144 may include openings that extend between an exterior surface of thecasing 140 and the central passage 142 of the casing 140 to facilitatethe flow of production substances, such as oil and gas, from thereservoir 102 into the central passage 142, or to facilitate the flow ofinjection substances, such as water, from the central passage 142 intothe formation 104. Although certain embodiments describe a perforation144 as one or more elongated holes in the casing 140 for the purpose ofillustration, embodiments can include any suitable form of perforations144. For example, perforations 144 may include in a mesh structuredefined by a plurality of relatively small holes that enable the flow ofsubstances across the holes, while also filtering out larger debris fromthe flowing substance.

In some embodiments, the casing 140 includes a casing pipe 150 and acasing liner 152, as illustrated at least in the detail section ofFIG. 1. The casing pipe 150 may include a hollow pipe that defines thecentral passage 142. The casing pipe 150 may include, for example, ahollow-cylindrical steel pipe. The casing liner 152 may include a rigidmaterial, such as cement, disposed in an annular region 154 locatedbetween an exterior surface 156 of the casing pipe 150 and the interiorwall 158 of the wellbore 120. The casing liner 152 may fill the annularregion 154 to secure the casing pipe 150 in place and seal the annularregion 154. This can help to inhibit substances, such as high pressuregases and liquids, from bypassing the central passage 142 and flowingthrough the annular region 154.

In some embodiments, the casing liner 152 is installed in the annularregion 154 by way of an additive manufacturing process. For example, thecasing liner 152 may be formed of cement that is deposited into place byway of a 3D cement printing process. FIGS. 2A and 2B are diagrams thatillustrate top and side section views of an example casing liner 152formed by way of an additive manufacturing process in accordance withone or more embodiments. In the illustrated embodiment, a casing linerprinting system 200 includes a print head 202 positioned in the annularregion 154 of the wellbore 120. The print head 202 may include one ormore nozzles 204 (for example, nozzles 204 a-204 e) coupled to acylindrical collar 206 disposed about the exterior surface 156 of thecasing pipe 150. During a casing liner printing operation of a casingoperation, the casing liner printing system 200 may be operated to ejectcasing liner material 210 from the nozzles 204 to form (or “print”) thecasing liner 152. For example, during a casing liner printing operation,the print head 202 may be rotated about the casing pipe 150 and alongitudinal axis 208 of the wellbore 120 (as illustrated by the arrow212) as casing liner material 210, such as cement, is ejected from thenozzles 204 to deposit the casing liner material 210 in particularlocations to form at least a first layer 214 a of the casing liner 152in the annular region 154.

In some embodiments, multiple rotational passes of the print head 202are made in coordination with the print head 202 being advanced along alength of the wellbore 120 (for example, parallel to the longitudinalaxis 208 of the wellbore 120) to deposit multiple casing liner layers214 of the casing liner material 210 (for example, layers 214 a-214 e)to form the casing liner 152. Continuing with the prior example, duringa casing liner printing operation, after the first layer 214 a is formedby way of a first rotational pass of the print head 202 about the casingpipe 150, the print head 202 may be advanced longitudinally along thelength of the wellbore 120 (as illustrated by the arrow 216) (forexample, parallel to a longitudinal axis 208 of the wellbore 120) by adistance equal to a thickness of a second layer 214 b of the casingliner 152 to be formed, and again be rotated about the casing pipe 150(as illustrated by the arrow 212) while ejecting casing liner material210 from the nozzles 204 to deposit the casing liner material 210 inparticular locations to form the second layer 214 b of the casing liner152 in the annular region 154. A similar iterative layering approach canbe conducted to form additional layers of the casing liner 152, such aslayers 214 c-214 e. The layers 214 a-214 e may together form the casingliner 152 across a depth interval 218. The resulting casing liner layers214 and casing liner 152 may be referred to as “printed” casing linerlayers 214 and a “printed” casing liner 152, respectively. Although onlyfive layers (layers 214 a-214 e) of the casing liner 152 are discussedfor the purpose of illustration, embodiments can include any suitablenumber of layers to form the printed casing liner 152 across a givendepth interval. Although embodiments describe advancing the print head202 vertically in an incremental manner after completing a rotationalpass about the wellbore 120, embodiments can include any suitable pathof advancement of the print head 202 to form the casing liner 152. Forexample, the print head 202 may be advanced vertically as it is rotatedabout the wellbore 120 to, for example, form a contiguous helical layerof casing liner material 210 across a depth interval.

In some embodiments, the operation of the print head 202, including thepositioning and movement of the print head 202, the alignment anddirection of the nozzles 204, and the rate of the ejection of the casingliner material 210 from the nozzles 204 is controlled by the wellcontrol system 122, to provide for the deposition of the casing linermaterial 210 in specific locations. In some embodiments, each of thenozzles 204 includes a flow sensor and deposition sensor that can detectand report a flow rate of the casing liner material 210 from the nozzleand a location of the deposition of the casing liner material 210, andthe flow rate information and deposition information can be used by thewell control system 122 to determine whether the casing liner material210 has been appropriately placed.

In some embodiments, the casing liner 152 contains integrated structuresformed within the casing liner material 210. For example, the casingliner 152 may include a cementitious matrix formed of a cement casingliner material 210 and one or more elements forming integratedstructures within the cement casing liner material 210. FIG. 3 is adiagram that illustrates a section view of an example of the casingliner 152 having integrated structures 162 formed within the casingliner material 210 in accordance with one or more embodiments. In someembodiments, an integrated structure 162 includes a void in thedeposited casing liner material 210 that is filled with a volume of asubstance other than the casing liner material 210, such as a gas,liquid or solid. For example, the casing liner 152 may be formed of acement casing liner material 210 and integrated structures 162 thatinclude pockets of a polymer formed in the cement casing liner material210. In some embodiments, an integrated structure 162 may simply includea formed pocket of air, void of the casing liner material 210.

FIGS. 4A and 4B are diagrams that illustrate top and side section viewsof an example of the casing liner 152 including integrated structures162 formed by way of an additive manufacturing process, in accordancewith one or more embodiments. In some embodiments, the print head 202may include a first subset of the nozzles 204 (for example, nozzles 204a-204 e) for depositing a first material, such as a cement casing linermaterial 210, and a second subset of the nozzles 204 (for example,nozzles 204 f-204 j) for depositing an integrated structure material400, such as a polymer, for forming integrated structures 162. The firstsubset of the nozzles 204 may include a first row of nozzles extendingradially from the cylindrical collar 206 and the second subset of thenozzles 204 may include a second row of nozzles offset from the firstrow of nozzles. For example, the first subset of the nozzles 204 mayinclude nozzles 204 a-204 e forming a first row of the nozzles 204distributed along a first axis 211 a extending radially from thecylindrical collar 206 and the second subset of the nozzles 204 mayinclude nozzles 204 f-204 j forming a second row of the nozzles 204distributed along a second axis 211 b offset from the first axis 211 a.In such an embodiment, one row of nozzles may “lead” with the second rowof nozzles “following” or “trailing”. For example during clockwiserotation of the print head 202, the second row of nozzles 204 may leadwith the first row of nozzles 204 following, such that the first andsecond rows of nozzles pass over an area in sequence, one after theother. In some embodiments, the nozzles 204 of each of the rows ofnozzles have the same radial distribution such that the two sets ofnozzles 204 pass over the same radial locations. For example, thenozzles 204 a-204 e may be arranged to follow the same circular path inthe annular region 154 as nozzles 204 f-204 j, respectively. This mayenable different materials to be deposited in a given area in a singlerotational pass of the print head 202. For example, where the nozzles204 a-204 e are employed to deposit a first material (for example,cement) and the nozzles 204 f-204 j are employed to deposit a secondmaterial (for example, a polymer), either of the first or secondmaterial may be deposited in each area of the annular region 154 bycontrolling each set of the nozzles 204 to eject either the first orsecond material in each area. Although two rows are described for thepurpose of illustration, any suitable arrangement of nozzles 204 may beemployed. For example, three offset rows of nozzles 204 may be employed,with each of the three rows being operated to eject first, second andthird materials respectively.

During a casing liner printing operation, the casing liner printingsystem 200 may be operated to eject casing liner material 210 from thefirst subset of the nozzles 204 (for example, from nozzles 204 a-204 e)and to eject integrated structure material 400 from the second set ofthe nozzles 204 (for example, nozzles 204 f-204 j) to form the casingliner 152. For example, referring to FIGS. 4A and 4B, during a casingliner printing operation, in a first pass, the print head 202 may berotated about the casing pipe (as illustrated by the arrow 212) ascasing liner material 210, such as cement, is ejected from the nozzles204 a-204 e to deposit the casing liner material 210 in particularlocations to form the first layer 214 a′ of the casing liner 152 in theannular region 154. In second, third and fourth passes, the print head202 may be rotated about the casing pipe 150 and the longitudinal axis208 of the wellbore 120 (as illustrated by the arrow 212) as the casingliner material 210 is ejected from the nozzles 204 a-204 e to depositthe casing liner material 210 in the shaded portions of the second,third, and fourth layers 214 a′, 214 b′ and 214 c′, respectively, and asintegrated structure material 400, such as a polymer, is ejected fromthe nozzles 204 f-204 j to deposit the integrated structure material 400in the unshaded portions of the second, third, and fourth layers 214 b′,214 c′ and 214 d′, respectively, to form the second, third, and fourthlayers 214 b′, 214 c′ and 214 d′ respectively of the casing liner 152 inthe annular region 154. In a fifth pass the print head 202 may berotated about the casing pipe 150 and the longitudinal axis 208 of thewellbore 120 (as illustrated by the arrow 212) as the casing linermaterial 210 is ejected from the nozzles 204 a-204 e to deposit thecasing liner material 210 in particular locations to form a fifth layer214 e′ of the casing liner 152 in the annular region 154. Although acertain shape of integrated structure is described for the purpose ofillustration, various shapes and arrangements of integrated structurescan be formed using the additive manufacturing processes described, orsimilar processes.

In some embodiments, the integrated structures 162 are provided tomodify mechanical properties of the casing liner 152. For example, theintegrated structures 162 can be strategically positioned, shaped andfilled with particular types of substances to effect particularmodifications to the mechanical properties of the casing liner 152, suchas ductility or impact resistance. For example, the integratedstructures 162 may include pockets filled with a substance, such as apolymer, having a Young's Modulus that is less than a Young's Modulus ofthe casing liner material 210 to effectively reduce the Young's Modulusof the resulting casing liner 152 to a level below that of the casingliner material 210. As a further example, the integrated structures 162may be oriented to extend in a radial direction (for example,perpendicular to the casing pipe 150 or the longitudinal axis 208 of thewellbore 120) or longitudinal direction (for example, parallel to thecasing pipe 150 or the longitudinal axis 208 of the wellbore 120) in theannular region 154. Such integrated structures 162 may reduce theYoung's Modulus of the casing liner 152 in the radial or longitudinaldirection relative to that of a casing liner 152 formed of a solidcement casing liner material 210. This can, for example, facilitate thecasing liner 152 deforming radially or longitudinally to absorbvariations in radial or longitudinal stresses acting on the casing liner152, without cracking or otherwise failing.

FIGS. 5A and 5B are diagrams that illustrate top and section views of anexample of the casing liner 152 containing radially oriented integratedstructures 162 formed within casing liner material 210 in accordancewith one or more embodiments. In the illustrated embodiment, each of theoriented integrated structures 162 includes an elongated void formed inthe casing liner material 210 that extends in a radial direction (forexample, perpendicular to the casing pipe 150 and the longitudinal axis208 of the wellbore 120) in the annular region 154. For example, eachthe oriented integrated structures 162 of FIG. 5A includes an elongatedelliptical shaped void extending radially along a width of the annularregion 154 in a lateral direction, generally transverse to thelongitudinal axis 208 of the wellbore 120 and the casing pipe 150. Eachof the oriented integrated structures 162 may be encapsulated within thecasing liner material 210. The void of the integrated structures 162 maybe filled with a substance, such as a polymer, having a Young's Modulusthat is less than a Young's Modulus of the casing liner material 210 andthus may reduce the Young's Modulus of the casing liner 152 in theradial direction, relative to that of a solid casing liner formed ofonly the casing liner material 210. As described, each of the orientedintegrated structures 162 may be formed by not depositing the casingliner material 210 in the region of the oriented integrated structure162, or by depositing integrated structure material 400 into the regionof the oriented integrated structure 162 in place of the casing linermaterial 210, for example.

FIGS. 6A and 6B are diagrams that illustrate top and side section viewsof an example of the casing liner 152 containing longitudinally orientedintegrated structures 162 formed within casing liner material 210 inaccordance with one or more embodiments. In the illustrated embodiment,each of the longitudinally oriented integrated structures 162 includesan elongated void formed in the casing liner material 210 that extendsin a longitudinally direction (for example, parallel to the casing pipe150 and the longitudinal axis 208 of the wellbore 120) in the annularregion 154. For example, each the oriented integrated structures 162 ofFIG. 5B includes an elongated elliptical shaped void extendinglongitudinally along a length of the annular region 154 in a directiongenerally parallel to the longitudinal axis 208 of the wellbore 120 andthe casing pipe 150. Each of the oriented integrated structures 162 maybe encapsulated within the casing liner material 210. The void of theintegrated structures 162 may be filled with a substance, such as apolymer, having a Young's Modulus that is less than a Young's Modulus ofthe casing liner material 210 and thus may reduce the Young's Modulus ofthe casing liner 152 in the longitudinal direction, relative to that ofa solid casing liner 152 formed of only the casing liner material 210.As described, each of the oriented integrated structures 162 may beformed by not depositing the casing liner material 210 in the region ofthe oriented integrated structure 162, or by depositing integratedstructure material 400 into the region of the oriented integratedstructure 162 in place of the casing liner material 210, for example.Although elliptically shaped integrated structures 162 are described forthe purpose of illustration, embodiments may include other suitablyshaped integrated structures, as described here.

The integrated structure material 400 that forms the integratedstructures 162 may be any of a variety of substances, including gases,liquids or solids. Examples gases include air, nitrogen and helium.Examples of liquids include water, brine (for example, calcium chlorideand calcium bromide potassium chloride), organic liquids (for example,N-butyl-pyrrolidone, N-ethyl pyrrolidone, and N-methyl pyrrolidone),organic ionic liquids (for example, imidazolium salts such asbutyl-imidazolium tetrafluoroborate), and silicon containing liquids(for example, siloxanes and colloidal silicas). Further examples ofliquids can include monomeric liquids, which when activated,cross-polymerize to make liquids with modified rheological properties.Examples of solids include metals (for example, steel, aluminum, andnickel-aluminum alloys), polymers (for example, polyesters,polycarbonates, polyanhydrides, polyamides, polyaramids andpolyurethanes), and cementitious composites (for example, Portlandcement, Sorel cement, aluminate cements, and pozzolan/lime cements).Although the casing liner material 210 is often described as cement forthe purpose of illustration, the casing liner material 210 may includeany suitable material, such as an epoxy, phenolic resin, monomericspecies such as acrylamide, which when activated, polymerize to rendersolid materials. In some embodiments, these materials can be eitherhard-set materials which are solvent-free or materials containingsolvent which cure as gels. Further examples include layered composites.These can include combinations of solids, gases or liquids, such asthose described above, arranged into layers. Such layered composites mayprovide advantageous mechanical or chemical properties for conditionswithin the well-bore.

In some embodiments, an integrated structure 162 is formed in thewellbore independent of the depositing of the casing liner material 210.For example, an integrated structure 162 formed of the integratedstructure material 400, such as a honeycomb shaped structure formed of apolymer, may be printed in the annular region 154 of the wellbore 120 tofrom an integrated structure 162 having one or more contiguous voidsformed in the structure material. The casing liner material 210, such ascement, may then be injected into the one or more contiguous voids ofthe integrated structure 162 to form the casing liner 152 including amatrix of the casing liner material 210 and the material of theintegrated structure 162. In some embodiments, the casing liner material210 is deposited in the wellbore independent of the deposition of theintegrated structure material 400. For example, the casing linermaterial 210, such as cement, may be printed in the annular region 154of the wellbore 120 with one or more contiguous integrated voidstructures formed in the casing liner material, such as a contiguoushoneycomb shaped void structure. An integrated structure material 400,such as a polymer, may then be injected into the one or more contiguousintegrated void structures of the printed casing liner material 210 toform the casing liner 152 including a matrix of the casing linermaterial 210 and the material of the integrated structure 162.

FIGS. 7A-7N illustrate example integrated structures 162 (includingintegrated structures 700 a-700 n) in accordance with one or moreembodiments. The arrangement of the integrated structures 162 may beadapted to provide characteristics that are suitable in the wellboreenvironment in which they are disposed. For example, the integratedstructures can include various patterns and can be formed of certainmaterials or combinations of different materials. In some embodiments,the integrated structures 700 a-700 n include structural elements 702and corresponding void regions 704. The void regions 704 may include oneor more contiguous channels or regions within the structural elements702 of the respective structure. FIG. 7A illustrates a honeycomb shapedintegrated structure 700 a deposited in a wellbore and havinglongitudinally oriented hexagonal structural elements 702 andcorresponding longitudinally oriented hexagonal void regions 704. FIG.7B illustrates a honeycomb shaped integrated structure 700 b havingradially oriented hexagonal structural elements 702 and correspondingradially oriented hexagonal void regions 704. FIG. 7C illustrates a meshshaped integrated structure 700 c having radially oriented structuralelements 702 and corresponding radially oriented cylindrical voidregions 704. FIG. 7D illustrates a mesh shaped integrated structure 700d having radially oriented rectangular structural elements 702 andcorresponding radially oriented rectangular void regions 704. FIG. 7Eillustrates a mesh shaped integrated structure 700 e having radiallyoriented angular structural elements 702 and corresponding radiallyoriented angular void regions 704. FIG. 7F illustrates a mesh shapedintegrated structure 700 f having radially oriented polygonal structuralelements 702 and corresponding radially oriented polygonal void regions704. FIG. 7G illustrates a mesh shaped integrated structure 700 g havinglongitudinal and radially oriented patterned rectangular structuralelements 702 and corresponding longitudinal and radially orientedpatterned rectangular void regions 704. FIG. 7H illustrates a meshshaped integrated structure 700 h having radially oriented wavestructural elements 702 and corresponding radially oriented wave voidregions 704. FIG. 7I illustrates a mesh shaped integrated structure 700i having radially oriented spiral structural elements 702 andcorresponding radially oriented spiral void regions 704. FIG. 7Jillustrates a mesh shaped integrated structure 700 j having radiallyoriented circular structural elements 702 of varying radial lengths andcorresponding radially oriented circular void regions 704. FIG. 7Killustrates a mesh shaped integrated structure 700 k having radiallyoriented rectangular block structural elements 702 of varying radiallylengths and corresponding radially oriented void regions 704. FIG. 7Lillustrates a mesh shaped integrated structure 700 l having radiallyoriented prismic block structural elements 702 of varying radiallylengths and corresponding radially oriented void regions 704. FIG. 7Millustrates a mesh shaped integrated structure 700 m having a pattern ofradially oriented rectangular block structural elements 702 andcorresponding radially oriented void regions 704. FIG. 7N illustrates amesh shaped integrated structure 700 n having a pattern of radiallyoriented rectangular block structural elements 702 (for example,different subsets of the block structural elements 702 being formed ofdifferent materials, as indicated by the varied shading of subsets ofthe blocks) and corresponding radially oriented void regions 704.Although certain arrangements of integrated structures 162 are describedfor the purpose of illustration, the arrangements can have any suitableshape, and be formed of any suitable material. For example, thearrangements of integrated structures 162 can include spiral structures,brick layered structures, circular structures, prismic structures, orother geometric shapes, and can include brick patterns, mosaic patterns,parquet patterns, patterns with triangles, circles, squares, or othergeometric patterns. The arrangements of integrated structures 162 can beformed of one of or a combination of liquids, solids, and gases.

As described, in some embodiments, the integrated structures 700 a-700 nmay be formed by way of an additive manufacturing technique, such asthree-dimensional 3D printing. For example, an integrated structure 162formed of the integrated structure material 400, such as a honeycombshaped integrated structure 700 a or 700 b formed of a polymer, isprinted in the annular region 154 of the wellbore 120 using an additivemanufacturing technique. A casing liner material 210, such as cement,may be injected into the annular region 154 and the void regions 704 toform the casing liner 152 including a matrix of the casing linermaterial 210 and the integrated structure material 400 of the integratedstructure 162. In some embodiments, the casing liner material 210 isplaced to define a structure having voids, and the integrated structurematerial 400 is deposited in the resulting void regions. For example, acasing liner material 210, such as cement, having a structure consistentwith the structural elements 702 of the integrated structure 162, suchas the honeycomb shaped integrated structure 700 a or 700 b, may beprinted in the annular region 154 of the wellbore 120 using an additivemanufacturing technique, such as 3D printing, to form printed casingliner material 210 having one or more voids formed in the casing linermaterial that corresponds to the void regions 704 of the integratedstructure 162, such as the honeycomb shaped voids 704 of integratedstructure 700 a or 700 b. An integrated structure material 400, such asa polymer, may be injected into the void regions 704 formed in theprinted casing liner material 210 to form the casing liner 152 includinga matrix of the casing liner material 210 and the integrated structurematerial 400 of the integrated structure 162. Although a honeycomb shapeis discussed for the purpose of illustration, embodiments can employ anysuitable structural arrangement, such as those of any of the integratedstructures 700 a-700 n.

FIG. 8 is a flowchart that illustrates a method 800 of printing a casingliner in accordance with one or more embodiments. The method 800 maygenerally include drilling a wellbore into a subsurface formation (block802), positioning casing pipe in the wellbore (block 804), andconducting a cementing operation including additive manufacture of acasing liner (block 806). In some embodiments, drilling a wellbore intoa subsurface formation (block 802) includes drilling the wellbore 120into the formation 104 and the reservoir 102 as described here. Forexample, the well control system 122 may control a drilling rig to drillthe wellbore 120 into the formation 104 and the reservoir 102 along agiven wellbore trajectory. In some embodiments, positioning casing pipein the wellbore (block 804) includes positioning the casing pipe 150into the wellbore 120. For example, the well control system 122 maycontrol a drilling rig to lower the casing pipe 150 into a given depthinterval of the wellbore 120. In some embodiments, conducting acementing operation including additive manufacture of a casing liner(block 806) includes forming the casing liner 152 in the annular region154 by way of an additive manufacturing process, such as 3D printing ofthe casing liner material 210, or the casing liner material 210 and theintegrated structure material 400, as described here, to form the casingliner 152 without or with integrated structures 162. For example, thewell control system 122 may control the casing liner printing system 200to deposit the casing liner material 210, or the casing liner material210 and the integrated structure material 400, as described here, toform the casing liner 152 without integrated structures 162 (forexample, as described with regard to at least FIGS. 2A and 2B) or withintegrated structures 162 (for example, as described with regard to atleast FIGS. 3-7).

In some embodiments, additive manufacturing can be employed tomanufacture a tubular, such as casing pipe or production tubing inplace. For example, the casing liner printing system 200 may be operatedto print both the casing liner 152 and the casing pipe 150 downhole, asa print head of the casing liner printing system 200 is advanced throughthe wellbore 120. This can, for example, enable a single casing printingoperation to replace the running of the casing pipe 150, such as steelpipe, into the wellbore 120 and the separate installation of the casingliner, such as cement, into the annular region 154. FIGS. 9A and 9B arediagrams that illustrate top and side section views of an example casing140 formed by way of an additive manufacturing process in accordancewith one or more embodiments. In the illustrated embodiment, a casingprinting system 900 includes a casing print head 902 positioned in thewellbore 120. The casing print head 902 may include multiple nozzles 904(for example, nozzles 904 a-904 g). During a casing printing operation,the casing printing system 900 may be operated to eject casing linermaterial 210 from a first subset of the nozzles 904 (for example, fromnozzles 904 a-904 e) and to eject casing pipe material 910 from a secondsubset of the nozzles 904 (for example, nozzles 904 f and 904 g) to formthe casing pipe 150. For example, during a casing printing operation,the print head 902 may be rotated about the longitudinal axis 208 of thewellbore 120 (as illustrated by the arrow 912) as casing liner material210, such as cement, is ejected from a first subset of the nozzles 904(for example, nozzles 904 a-904 e) and casing pipe material 910, such assteel, is ejected from a second subset of the nozzles 204 (for example,nozzles 904 f and 904 g) to simultaneously deposit the casing linermaterial 210 and the casing pipe material 910 in particular locations toform at least a first layer 914 a of the casing 140 in the wellbore 120.

In some embodiments, multiple rotational passes of the print head 902are made in coordination with the print head 902 being advanced alongthe length of the wellbore 120 to deposit multiple layers of casingliner material 210 and casing pipe material 910 to form the casing liner152 and the casing pipe 150 in the wellbore 120. Continuing with theprior example, during a casing printing operation, after the first layer914 a is formed by way of a first rotational pass of the print head 902about the wellbore 120, the print head 902 may be advancedlongitudinally along the length of the wellbore 120 (for example,parallel to the longitudinal axis 208 of the wellbore 120) (asillustrated by the arrow 916) by a distance equal to a thickness of asecond layer 914 b of the casing 140 to be formed, and again be rotatedabout the longitudinal axis 208 of the wellbore 120 (as illustrated bythe arrow 912) as casing liner material 210, such as cement, is ejectedfrom a first subset of the nozzles 204 (for example, nozzles 904 a-904e) and casing pipe material 910, such as steel, is ejected from a secondsubset of the nozzles 204 (for example, nozzles 904 f and 904 g) tosimultaneously deposit the casing liner material 210 and the casing pipematerial 910 in particular locations to form at least a second layer 914b of the casing 140 in the wellbore 120. A similar iterative layeringapproach can be conducted to form additional layers 914 of the casingliner 152. For example, additional layers 914 c-914 e of the casing 140may be formed to form the casing 140 across a depth interval 918. Theresulting casing 140 may be referred to as “printed” casing. Althoughonly five layers (914 a-914 e) of the casing 140 are discussed for thepurpose of illustration, embodiments can include any suitable number oflayers to form the printed casing 140 across a given depth interval.Although embodiments describe advancing the print head 902 vertically inan incrementally manner, after completing a rotational pass about thewellbore 120, embodiments can any suitable path of advancement of theprint head 902 to form the casing 140. For example, the print head 902may be advanced vertically as it is rotated about the wellbore 120 to,for example, form a contiguous helical layer that forms the printedcasing 140 across a depth interval. Although a casing operation isdescribed for the purpose of illustration, embodiments can includeforming other types of tubular members in a similar manner. For example,a production tubing may be formed downhole alone, or in conjunction withforming of casing (for example, a production tubing with a casing pipeand a casing liner surrounding the production tubing). In such anembodiment, nozzles may be provided at radial locations corresponding tothe walls of the production tubing, and may eject production tubingmaterial, such as steel, to form the production tubing in a mannersimilar to that described with regard to the casing 140.

In some embodiments, a casing printing operation can include printingintegrated structures into the casing 140. For example, a casingprinting operation can include printing integrated structures similar tothose discussed with regard to at least FIGS. 3-7 into the casing liner152 of the printed casing 140. In some embodiments, the integratedstructures can include perforations. Perforations may include contiguousvoids that extend radially through the casing 140 (for example, from aninterior wall of the printed casing pipe 150 to an exterior surface ofthe printed casing liner 152) to define openings that extend between anexterior of the casing 140 and the central passage 142 of the casing140. A perforation may facilitate the flow of production substances,such as oil and gas, from the reservoir 102 into the central passage 142or to facilitate the flow of injection substances, such as water, fromthe central passage 142 into the formation 104. FIG. 10 is a diagramthat illustrates printed casing 140 having integrated structures 162,including perforations 144, in accordance with one or more embodiments.In some embodiments, the perforations 144 may be formed of a solidsubstance that initially inhibits flow through the perforation, but thatcan be dissolved or otherwise removed to enable the flow of fluids therethrough. For example, a perforation 144 may be formed by printing apolymer into a void region that defines the perforation 144, and thepolymer may later be exposed to a chemical that dissolves the polymer,or an elevated temperature that melts the polymer, leaving a passagedefined by the void. Although individual elongated perforations aredescribed for the purpose of illustration, embodiments can include anysuitable form of perforation. For example, a perforation 144 may bedefined by an integrated mesh (or “screen”) printed into the casing pipe150 and an adjacent opening(s) formed in the casing liner 152. The meshmay inhibit debris from traveling between the surrounding portion of theformation and the central passage 142 of the casing 150.

FIG. 11 is a flowchart that illustrates a method 1100 of printing acasing in accordance with one or more embodiments. The method 1100 maygenerally include drilling a wellbore into a subsurface formation (block1102) and conducting a casing operation including additive manufactureof a casing (block 1104). In some embodiments, drilling a wellbore intoa subsurface formation (block 1102) includes drilling the wellbore 120into the formation 104 and the reservoir 102 as described here. Forexample, the well control system 122 may control a drilling rig to drillthe wellbore 120 into the formation 104 and the reservoir 102 along agiven wellbore trajectory. In some embodiments, conducting a casingoperation including additive manufacture of a casing (block 1104)includes forming the casing 140 in the wellbore 120 by way of anadditive manufacturing process, such as 3D printing of the casing pipematerial 910, the casing pipe material 910 and the casing liner material210, or the casing pipe material 910, the casing liner material 210 andthe integrated structure material 400, as described here, to form thecasing 140, including the casing pipe 150 and the casing liner 152without or with integrated structures 162. For example, the well controlsystem 122 may control the print head 902 to deposit the casing pipematerial 910, the casing pipe material 910 and the casing liner material210, or the casing pipe material 910, the casing liner material 210 andthe integrated structure material 400, as described here, to form thecasing 140, including the casing pipe 150 and the casing liner 152without or with integrated structures 162. Although a casing operationis described for the purpose of illustration, embodiments can includeforming other types of tubular members in a similar manner. For example,a production tubing may be formed downhole alone, or in conjunction withforming of casing (for example, a production tubing with a casing pipeand a casing liner surrounding the production tubing). In such anembodiment, nozzles may be provided at radial locations corresponding tothe walls of the production tubing, and may eject production tubingmaterial, such as steel, to form the production tubing in a mannersimilar to that described with regard to the casing 140.

Although certain embodiments describe additive manufacturing includinglayering in a bottom-up approach (for example, forming a subsequentlayer on top of (or on an up-hole side of) a previous layer) to form aprinted casing liner 152 or printed casing 140, embodiments can employany suitable technique to form a printed casing liner 152 or a printedcasing 140. For example, embodiments can include layering in a top-downapproach (for example, forming a subsequent layer underneath (or on adown-hole side of) a previous layer) to form a printed casing liner 152or a printed casing 140.

FIG. 12 is a diagram that illustrates an example computer system (or“system”) 2000 in accordance with one or more embodiments. In someembodiments, the system 2000 is a programmable logic controller (PLC).The system 2000 may include a memory 2004, a processor 2006 and aninput/output (I/O) interface 2008. The memory 2004 may include one ormore of non-volatile memory (for example, flash memory, read-only memory(ROM), programmable read-only memory (PROM), erasable programmableread-only memory (EPROM), electrically erasable programmable read-onlymemory (EEPROM)), volatile memory (for example, random access memory(RAM), static random access memory (SRAM), synchronous dynamic RAM(SDRAM)), and bulk storage memory (for example, CD-ROM or DVD-ROM, harddrives). The memory 2004 may include a non-transitory computer-readablestorage medium having program instructions 2010 stored thereon. Theprogram instructions 2010 may include program modules 2012 that areexecutable by a computer processor (for example, the processor 2006) tocause the functional operations described, such as those described withregard to the well control system 122, the method 800 or the method1100.

The processor 2006 may be any suitable processor capable of executingprogram instructions. The processor 2006 may include a centralprocessing unit (CPU) that carries out program instructions (forexample, the program instructions of the program module(s) 2012) toperform the arithmetical, logical, and input/output operationsdescribed. The processor 2006 may include one or more processors. TheI/O interface 2008 may provide an interface for communication with oneor more I/O devices 2014, such as a joystick, a computer mouse, akeyboard, and a display screen (for example, an electronic display fordisplaying a graphical user interface (GUI)). The I/O devices 2014 mayinclude one or more of the user input devices. The I/O devices 2014 maybe connected to the I/O interface 2008 via a wired connection (forexample, Industrial Ethernet connection) or a wireless connection (forexample, Wi-Fi connection). The I/O interface 2008 may provide aninterface for communication with one or more external devices 2016, suchas sensors, valves, motors, other computers and networks. In someembodiments, the I/O interface 2008 includes one or both of an antennaand a transceiver. In some embodiments, the external devices 2016include the casing liner printing system 200 or the casing printingsystem 900.

Further modifications and alternative embodiments of various aspects ofthe disclosure will be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only and is for the purpose of teaching those skilled inthe art the general manner of carrying out the embodiments. It is to beunderstood that the forms of the embodiments shown and described hereare to be taken as examples of embodiments. Elements and materials maybe substituted for those illustrated and described here, parts andprocesses may be reversed or omitted, and certain features of theembodiments may be utilized independently, all as would be apparent toone skilled in the art after having the benefit of this description ofthe embodiments. Changes may be made in the elements described herewithout departing from the spirit and scope of the embodiments asdescribed in the following claims. Headings used here are fororganizational purposes only and are not meant to be used to limit thescope of the description.

It will be appreciated that the processes and methods described here areexample embodiments of processes and methods that may be employed inaccordance with the techniques described here. The processes and methodsmay be modified to facilitate variations of their implementation anduse. The order of the processes and methods and the operations providedmay be changed, and various elements may be added, reordered, combined,omitted, modified, etc. Portions of the processes and methods may beimplemented in software, hardware, or a combination thereof. Some or allof the portions of the processes and methods may be implemented by oneor more of the processors/modules/applications described here.

As used throughout this application, the word “may” is used in apermissive sense (that is, meaning having the potential to), rather thanthe mandatory sense (that is, meaning must). The words “include,”“including,” and “includes” mean including, but not limited to. As usedthroughout this application, the singular forms “a”, “an,” and “the”include plural referents unless the content clearly indicates otherwise.Thus, for example, reference to “an element” may include a combinationof two or more elements. As used throughout this application, the term“or” is used in an inclusive sense, unless indicated otherwise. That is,a description of an element including A or B may refer to the elementincluding one or both of A and B. As used throughout this application,the phrase “based on” does not limit the associated operation to beingsolely based on a particular item. Thus, for example, processing “basedon” data A may include processing based at least in part on data A andbased at least in part on data B, unless the content clearly indicatesotherwise. As used throughout this application, the term “from” does notlimit the associated operation to being directly from. Thus, forexample, receiving an item “from” an entity may include receiving anitem directly from the entity or indirectly from the entity (forexample, via an intermediary entity). Unless specifically statedotherwise, as apparent from the discussion, it is appreciated thatthroughout this specification discussions utilizing terms such as“processing,” “computing,” “calculating,” “determining,” or the likerefer to actions or processes of a specific apparatus, such as a specialpurpose computer or a similar special purpose electronicprocessing/computing device. In the context of this specification, aspecial purpose computer or a similar special purpose electronicprocessing/computing device is capable of manipulating or transformingsignals, typically represented as physical, electronic or magneticquantities within memories, registers, or other information storagedevices, transmission devices, or display devices of the special purposecomputer or similar special purpose electronic processing/computingdevice.

What is claimed is:
 1. A method of forming a casing liner in a wellboreof a hydrocarbon well, the method comprising: disposing a casing linerprint head in an annular region located between a casing pipe disposedin a wellbore of a hydrocarbon well and a wall of the wellbore; andconducting a downhole lining operation comprising operating the casingliner print head to eject casing liner material into the annular regionto form, in the annular region, a casing liner comprising elongatedvoids formed in the casing liner material, wherein the elongated voidscomprise elongated voids extending in a radial direction more than in alongitudinal direction in the annular region, wherein the liningoperation comprises ejecting an integrated structure material to formthe elongated voids in the casing liner material, and wherein theintegrated structure material has a Young's Modulus that is less than aYoung's Modulus of the casing liner material.
 2. The method of claim 1,wherein the downhole lining operation comprises advancing the casingliner print head along a length of the wellbore and ejecting the casingliner material along a length of the annular region to form the casingliner along the length of the annular region.
 3. The method of claim 1,wherein the elongated voids comprise elongated voids extending in alongitudinal direction in the annular region.
 4. The method of claim 1,wherein the elongated voids are encapsulated within the casing linermaterial.
 5. The method of claim 1, wherein the elongated voids compriseelliptical shaped voids.
 6. The system of claim 1, wherein theintegrated structure material comprises a gas, liquid or solid.
 7. Thesystem of claim 1, wherein the integrated structure material comprises apolymer.
 8. The method of claim 1, wherein the casing liner materialcomprises a cementitious material.
 9. The method of claim 8, wherein thecasing liner material comprises casing cement.
 10. A method of forming acasing liner in a wellbore of a hydrocarbon well, the method comprising:disposing a casing liner print head in an annular region located betweena casing pipe disposed in a wellbore of a hydrocarbon well and a wall ofthe wellbore; and conducting a downhole cementing operation comprisingoperating the casing liner print head to eject casing cement into theannular region to form, in the annular region, a casing liner comprisingelongated voids formed in the cementitious material, wherein theelongated voids comprise elongated voids extending in a radial directionmore than in a longitudinal direction in the annular region, wherein thelining operation comprises ejecting an integrated structure material toform the elongated voids in the casing liner material, and wherein theintegrated structure material has a Young's Modulus that is less than aYoung's Modulus of the casing liner material.
 11. The method of claim10, wherein the downhole cementing operation comprises advancing thecasing liner print head along a length of the wellbore and ejecting thecasing liner material along a length of the annular region to form thecasing liner along the length of the annular region.